Method of manufacturing colored yarns



W. J. KERWIN, JR

Feb. 21, 1928. 1,660,129

METHOD OF MANUFACTURING COLORED YARNS Filed March 1. 1927 Patented Feb. 21, 1928.

UNITED STATES WILLIAM J. KERWIN, 31%., OF SOUTH DARTMOUTH, MASSACHUSETTS.

METHOD OF MANUFACTURING COLORED YARNS.

Application filed March 31, 1927. Serial No. 180,005.

This invention relates to a method of, and apparatus for, manufacturing colored yarns to produce various shaded or ombre effects, or various colored tints and hues therein.

In my Patent No. 1,572,148, granted Feb ruary 9, 1926, one method of producing the desired color effects is disclosed. Generally stated, that process consists in cutting sections from differently colored or shaded laps of fibrous material and disposing these sectionson the'moving apron of a card or like machine in a definite order so that the yarn produced, though greatly attenuated, will have the desired shading due to this arrangement. These laps are sheets of fibrous material of uniform width and generally uniform thickness and are wound into rolls of convenient size. The sections, some of which are triangular, are cut from these-laps by a pattern laid upon them. The sections when disposed on the apron constitute a-strip of uniform width. In this strip triangular, or triangular and rectangular sections of different colors or shades areplaced adjacent each other so that in the yarn. produced there will be a uniformly graduatedshading or blending from one color or shade to the other.

The commercial application of this patented mcthod, while producmg the desired results, involves a considerable amount of waste in material and a certain amount of excess labor which it is an obJect of the pres- ,cnt invention to avoid. The saving in labor.

realized by the present proposed methodwill be understood when the new method is OK- plained in detail hereinafter; the saving in material will be better understood from an explanation oft-he sources of waste accord ing to the former method. This explanation of some of the sources of waste follows:

First, the lap from which the sections are.

out while of generally uniform thickness over its entire length, is not of uniform thickness at every point in its length. Thus, there may be thin portions followed by thicker portions. In forming the lap on the card apron according to the patented invention, if too thick or thin portions occur they mustbe discarded and thrown back to the previous machine. The lap on the apron must be of uniform thickness when the apron moves at a given linear velocity to feed the material to the card, inv order to produce a sliver of uniform weight-throughout its length. 7 I

fieopnd, cutting out of the thick or thin sections involves the loss of a certain length of the lap on at least one side of the out if the length of the lap from the section last removed to'the cut is shorter than the shortest pattern section employed.

Third, the end portions of the lap in a roll are usually irregular, and since the pattern has straight sides, the ragged ends of the lap are wasted.

Fourth, the material in the lap is not well matted and frequently tears, or pulls apart transversely, and pieces break and fall off the edge. The sections of the lap at these points have to be cut out. This mutilation of the lap occurs both during the handling while cutting the sections and also when the rolls are stored for use, as they must be to some extent, to keep the card running should the machines producing the laps be temporarily disabled or be producing some other color or shadeof lap.

Besides the elimination of waste in" labor and material, the present invention has for an objectthe production of different sizes of yarn of the same type without a change of the apparatus employed.

Other objects will be apparent from the following description and accompanying illustration, in which:

Figure 1 is a side elevation of breaker and finisher carding machines of conventional type arranged in tandem and fitted for use with my improved method;

Figure 2 isa diagrammatic plan view of the top section of the enlarged feeding apron showing certain patterns or sections formed thereon; and p Figure 3 is a view similar to Fig; 2 but showing an additional superimposed pattern formed in outline over the first, for employ ment in making yarn of larger diameter.

Referring to Fig. 1 of the drawings, 12

designates a breaker card of usual type, and 13 a finisher card arranged in tandem therewith. Between the two cards is a cross feeding mechanism 14;, commonly called a scotch feeder, for transferring the sliver from the breaker to the finisher, and-at the dofler end of the finisher is a condenser 15. These several units of machinery may be of any suitable construction, the cards-being preferably of the full roller type as designated for operation under. what is termed the cotton waste or woolen system. i

In adapting the above described machines to the purpose of the present invention, it is only shades or colors tocar necessary to make a slight change in the construction of the breaker card. This alteration consists in extending the feed table 16 to several times its usual length whereby more surface is alii'orded for apportioning and laying out the ditl'erent colored or shaded sections of fibrous materialon the feed apron or conveyor '17. The conveyor is an endless belt type, preferably of the lat tice type, moving toward the card on its top surface, and any Well known means is provided for changing the linear speed of the conveyor relative to the speed of the card The scotch feeder 14 comprises 1. cans for delivering the slivers from the dotfer 18 of the breaker card 12 to an elevated conveyor 19 which transfers it to traversing carriage 2O acting to lay it at the back ot'the fi n-' isher card 13.

The condenser 15 employed Withthe finish or card may be of any suitable type, a tape condenser being illustrated as the present preferred form. The function of this unit to divide the Web from the finisher card dofier into strips which are carried along by tapes to the condenser rolls and rubbed into tr nds il-Ra i e is uin in F huge numbe of ends which are Wound upon jack spools 22' From the condenser 15' the roving is transferred to thespinning machines to be spun into yarn. For the spinning process I may employ ring spinning frames ,or mules, but such machines are Well known in the art and have no particular function related to the present method of manufacture, it is unnecessary to illustrate ordescribe the same in the present application.

A preferred arrangement of machinery for use with my improved method manutacture having been above described, the

method of carrying out the steps of the proc- The feature of the process descr bed in the patent referred .to,

will be explained.

fibers may be employed and these maybecoijnbined in varying proportions but will be sufficient for an understanding of the present invention to explain the simplest method with the use of fibers dyed in two contrasting colors or shades combined in equal parts. i i i i I According to the process of the patent. the lap on the apron of the card is formed from pieces cut to exact shape from a-[Webor lap fibers of uniform width and thickness,

and waste results, as pointed out. According to the present invention th s 1s eliminated by takingpieces of material of any shape or size and building up the sections on the apron. Indeed the stock may be in bunches or handfuls taken directly :trom'a vertical openeiyor from the front of the picker, in bulk, Without allowing the lap to form. i i v V In'order that the operator shall build up the'sections of proper sizes and shapes, a pattern is marl-:ed'on the apron 17. This pattern may be composed of sections of any desired configuration but the form illustrated consists of rectangles'and triangles, the triangles ot one color or shadebei-ng arranged upon either side of a rectangle otthe same color to form parallelograms or rhomboids taperingtou'ards their ends. Such a configuration is indicated inFigure 2 and consists of the rectangle B and the triangles G, C. An adjoining configuration of a second color or shade is composed of the rec-v tangle tions of alternate colors are thus continued in successive alternation about the entire length of the conveyor. Preferably, the sections are painted upon the surface ofthe conveyor.

A quantity of fibrous material of one color or shadeis spread out over oneolf the sectrons, say t), B, C- the quantity may consist of irregular pieces or batches. A like quantity of material of another color or shade is spread out toa uniform thicknesson the adjacent section D, E, D and so on. Should the material come in sheets of regular thickness but irregular sizes, the sheets are laid upon the marked sections and their edges pushed into contact. If necessary or desirable the sheets may be out or pulled apart by hand to cause them to fit'togethcr without leaving open spa es and also to con fine the material Within the enclosing lines of the sections. Alternatively a Weighed amount of loose material in batches'o't in discriminate shape and size maybe spread by. hand over the sections. it has been found that a moderately skilled Worker can distribute'thelmaterial quite evenly when gaging the thickness by sight and feel. Even if the material is spread so as to have small lumped areas, the average diameter of the rovings will not be affected to any extent so long as the thick or thin areas do not extend Usually the completely across the apron. thick andthin spots by this method of laying on the material offset each other.

The conveyor 17 is'of the type Which is adapted to be operated at different speeds in and the'triangles D, D. The sectovarythe size of roving produced, it being apparent that the-faster the conveyor travels the more material will be fed to "the" card within" a given time and the heavier h trand f ter se s me h l ness of materialspread on the apron to remain constant, it will be necessary to have an elongated pattern capable of holding more material if the shading of the yarn is to be kept uniform over a given length, when the conveyor speed .is increased. In Figure 3 there is shown such an elongated pattern painted in outline in two contrast ing colorsover the primary pattern already described. The superimposed pattern is similar in every way to the first. It consists of rectangles B and trianglesC, C of one color, and triangles D, D and rectangles E of a second color arranged as before in alternating rhomboids or parallelograms of such length and number as to occupy in an even number the entire length of the belt conveyor. By forming two or more patterns in superimposed fashion, the same conveyor used for slow feed and light yarns may be made to serve without change for rapid feed and heavier yarn.

The operation of machines to produce the desired type of yarn and the manner in which such yarn is knitted or woven to bring out the desired color effect in the fabric are completely described in my patent and well understood by those skilled in this art and need not be recounted here, since the present method as to those steps is the same as the method set forth in the patent.

It is to be understood that the invention is not limited to the exact details set forth, but includes modifications and changes coming within the scope of the appended claims.

The term colors as used in the claims is intended to cover the primary colors and combinations of suchcolors.

Having thus described the invention, what is claimed as new and desired to be secured by Letters Patent is: I

l. A feed conveyor for fiber parallelizing apparatus comprising an endless belt having a pattern provided upon its surface, said pattern consisting of a plurality of sections alternately arranged progressively along the length of the conveyor.

2. A feed conveyor for fiber parallelizing apparatus comprising an endless belt having pattern provided upon its surface, said pattern consisting of. a plurality of contrastingly colored sections arranged in alternate relation progressively along the length of the conveyor. 7

A feed conveyor for fiber parallelizing apparatus comprising an endless belt having a plurality of patterns provided upon its surface for selective utilization, each of said patterns consisting of a plurality of sections alternately arranged progressively along the length of the conveyor.

4. A feed conveyor for fiber parallelizing apparatus comprising an endless belt having a plurality of patterns provided upon its surface for selective utilization, each of said patterns consisting of a plurality of contrastingly colored sections arranged in alternate relation progressively along the length of the conveyor.

5. A feed conveyor for fiber parallelizing apparatus comprising an endless belt having a plurality of separately distinctive patterns provided upon its surface for selective utilization, one of said patterns consisting of a plurality of contiguous sections in contrast ing solid colors arranged in alternate relation progressively along the length of the conveyor and another of said patterns con sisting of a plurality of contiguous sections indicated in outline over the first pattern in alternate relation progressively along the length of the conveyor. I

6. A feed conveyor for fiber parallelizing apparatus comprising an endless belt having a pattern provided upon its surface, said pattern consisting of a plurality of tapering sections alternately arranged progressively along the length of the conveyor.

7. A feed conveyor for fiber parallelizing apparatus comprising an endless belt having a plurality of separately distinctive patterns provided upon its surface for selective utilization, one of said patterns consisting 'of a plurality of contiguous tapering sec tions in contrasting solid colors arranged in alternate relation progressively along the length of the conveyor and another of said patterns consisting of a plurality of contiguous tapering sections indicated in outline over the first pattern in alternate relation progressively along the length of the conveyor.

8. A feed conveyor for fiber parallelizing apparatus comprising an endless belt having a plurality of separately distinctive patterns provided upon its surface for selective utilization, each of said patterns consisting ofa pluralityof contiguous mutually distinctive tapering sections arranged in alternate relation progressively along the length of the conveyor, said patterns having sections of several lengths respectively adapting the patterns for utilization when the feed conveyor speed is changed to prod uce a different weight of stock.

9. In a method of manufacturing colored yarns, the steps consisting in providing an elongated pattern comprising a plurality of distinctive adjacent sections of definite configuration disposed in alternate relation progressively along the length of a feeding apron and filling in each section to a uni form depth with portions of fibrous material from bulk of different colors, each section being filled with a material of a color different from that of an adjacent section.

10. In a method of manufacturing colored yarns, the steps consisting in providing an elongated pattern comprising a plurality of tapering sections disposed in alternate relation progressively along the length of a feeding apron and filling in each section to a. uniform "depth with portions of fibrous material from bull: of different colors, each section being filied with a material of a color different from that of an adjacent section.

11. In the method of manufacturing colored yarns, the steps which comprise taking portions of fibrous material from bulk of different colors, and spreading the portions in sections of desired outlines upon a forming surface, each section being made up of fibrous-i material of the same color.

12. In the method of manufacturing colored yarns, the steps which comprise taking portions of fibrous material from bulk of different colors, and spreading the portions in sections of desired outlines upon a forming surface, the said sections being disposed in alternate relation progressively along the length of said forming surface, each section being made up of fibrous material of the same color.

13. In the method of manufacturing colored yarns, the steps which comprise taking portions of fibrous material from bulk of different colors, weighing the said portions, and spreading the weighed portions insections of desired outlines'upon a forming surface, each section being made up of fibrous material of the same color.

1 In the method of manufacturing colored yarns, the steps which comprise taking portions of fibrous material from bulk of different colors, weighing the said portions, and spreading the weighed portions in sections of desired outlines upon a forming surface, the said sections being disposed in alternate relation progressively along the length of said forming surface, each section being made up of fibrous material of the same color.

15. In the method of manufacturing colored yarns, the steps which comprise taking portions of fibrous material from bullr of different colors, and spreading the portions in tapering sections of desired outlines upon a forming surface, each section being made up of fibrous material of the same color.

tee-0, 9

16. Inthe method of manufacturing colored yarns, the steps which comprise taking portions of fibrous material from bulk of different colors, and spreading the portions in tapering sections of desired outlines upon a forming surface, the said sections being disposed in alternate relation progressively along the length of said forming surface, each section being made up of fibrous material of the same color.

17. In the method of manufacturing colored yarns, the steps which comprise providing a surface having a pattern thereon, and spreading portions of fibrous material taken from bulk of different colors in sections upon said pattern, each section being made up of fibrous material of the same color. 7 i

18. In the methodof manufacturing colored yarns, the steps which comprise providing a surface having a pattern thereon, and spreading portions of fibrous material taken from bulk 'ofdifierent colors insections upon said pattern, the said sections being disposed in alternate relation progressively along the length of said forming surface, each section being made 'up of fibrous material of the same color.'

19. In the method of manufacturing colored yarns, the steps which comprise taking portions of fibrous material from bulk of different colors, and spreading the portions of fibrous material taken from bulk of dif-v ferent colors intaperingsections upon said pattern, each section being made up of fibrous material of the same color. Y

20. In the method of manufacturing colored yarns, the steps which comprise tak ing portions of fibrous material from bulk of different colors, and spreading the pertions of fibrous material taken from bulk of different colors in tapering sections upon said pattern, the said sections being disposed in alternate relationprogressively along the length of said forming surface, each section being made up of fibrous materialof the same color. v I

In testimony whereof I hereunto affix my signature. WVILLIAM J. KERWIN, Jr. 

